Hatz Diesel 1D90W User manual

1D90V | 1D90W
www.HATZ-DIESEL.com
Hatz Diesel
CREATING POWER SOLUTIONS.
Translation of the
ORIGINAL
INSTRUCTION BOOK
IINNCCLLUUDDEESSSSUUPPPPLLEEMMEENNTTAALLIINNFFOORRMMAATTIIOONNTTOO
TTHHEEOOWWNNEERR’’SSMMAANNUUAALLFFOORRMMOODDEELLYYEEAARR22001155
EEPPAACCEERRTTIIFFIIEEDDNNOONNRROOAADDCCOOMMP
PRREESSSSIIOONN--
IIGGNNIITTIIOONNEENNGGIINNEESS..
IINNCCLLUUDDEESSSSUUPPPPLLEEMMEENNTTAALLIINNFFOORRMMAATTIIOONNFFOORR
TTHHEEUUSSEEOOFFEEPPAACCEERRTTIIFFIIEEDDEENNGGIINNEESSWWI
ITTHHIINN
CCAALLIIFFOORRNNIIAA..

1
A new HATZ diesel engine is ready to work for you
This engine is intended only for the purpose determined and tested by the manufacturer of the
equipment in which it is installed. Using it in any other manner contravenes the intended purpose.
For danger and damage due to this, Motorenfabrik HATZ assumes no liability. The risk is with the user
only. Use of this engine in the intended manner presupposes compliance with the maintenance and
repair instructions laid down for it. Noncompliance leads to engine breakdown.
Please study this Instruction Book before you start the engine for the first time: it will help you to
avoid accidents, to operate the engine correctly, to perform maintenance work and to keep the engine
operating at full efficiency for a very long time.
Please follow all maintenance references carefully including the schedule for Model Year 2015
EPA certified nonroad compression-ignition engines to prevent our environment.
Please pass this Instruction Manual on to the next user or to the following engine owner.
Always have service work performed by qualified specialists. To this effect, we recommend that you
consult one of the 500 HATZ service stations. There, your engine is repaired by staff who constantly
undergo training and who use both original HATZ spare parts and HATZ tools. The world-wide HATZ
service network is also available to you for consultation and spare parts supply.
For the address of your nearest HATZ service station, please refer to the attached list or the internet
under: www.hatz-diesel.com
The installation of inappropriate spare parts may cause problems. We cannnot accept any liability for
damage or consequential damage resulting therefrom.
Thus, we recommend that you use original HATZ spare parts. These parts are manufactured follow-
ing the strict HATZ specifications and ensure, thanks to their perfect fit and function, maximum oper-
ating reliability. For the reference number, please consult the attached spare part list or the internet
under: www.hatz-diesel.com. Please take the complete spare parts kits in Table M00 into account.
We reserve the right to make modifications in the course of technical progress.
MOTORENFABRIK HATZ GMBH & CO KG

Page
1. Important notes on safe operation
of the engine 3
2. Description of the engine 5
3. General information 6
3.1. Technical data 6
3.2. Transport 7
3.3 Instructions for installation 7
3.4. Load on engine 7
3.5. EPA / CARB - type plate 8
3.6. Emission-related installation
instructions 8
4. Operation 9
4.1. Before initial start-up 9
4.1.1. Engine oil 9
4.1.2. Fuel 10
4.1.3. Mechanical oil pressure monitor 11
4.2. Starting the engine 12
4.2.1. Preparations for starting 12
4.2.2. Electric starter 12
4.3. Engine use 13
4.4. Stopping the engine 14
5. Maintenance 15
5.1. Maintenace summary 15
5.2. Maintenance every 8 – 15
hours of operation 17
5.2.1. Check engine oil level 17
5.2.2. Check air intake point 17
5.2.3. Air cleaner blockage indicator 17
5.2.4. Checking cooling air zone 18
5.2.5. Checking the water trap 18
Page
5.3. Maintenance every 250
hours of operation 19
5.3.1. Changing engine oil, renewing oil filter 19
5.3.2. Checking and adjusting
valve clearances 20
5.3.3. Clean the cooling air system 21
5.3.4. Checking threaded connections 21
5.4. Maintenance every 500
hours of operation 22
5.4.1. Renewing fuel filter 22
5.4.2. Dry-type air cleaner maintenance 22
6. Malfunctions – Causes – Remedies 24
7. Work on the electrical system 28
8. Protective treatment 28
Declaration for Incorporation 29
SUPPLEMENTAL INFORMATION TO
THE OWNER’S MANUAL FOR Model
Year 2015 EPA CERTIFIED NONROAD
COMPRESSION IGNITION ENGINES 31
SUPPLEMENTAL INFORMATION TO
THE OWNER'S MANUAL FOR THE USE
OF EPA CERTIFIED ENGINES WITHIN
CALIFORNIA 43
2
Contents
This symbol identifies important safety precautions.
Please comply with these most carefully in order to avoid any risk of injury to persons or
damage to materials.
General legal requirements and safety regulations issued by the competent authorities or
industrial accident insurers must also be complied with.

3
1. Important notes on safe operation of the engine
HATZ diesel engines are economical, strongly built and long-lasting. They are therefore frequently
chosen for commercially and industrially operated equipment and machinery.
Since the engine forms part of the finished equipment or machine, its manufacturer will take all the
applicable safety regulations into account.
Nevertheless, we give below certain additional comments on operating safety, and would recommend
you to note them carefully.
Depending on the manner in which the engine is installed and its intended application, the equipment
manufacturer or operator may have to attach additional safety devices and prohibit potentially hazard-
ous aspects of operation, for example:
– Parts of the exhaust system as well as the surface of the engine are of course hot during operation
of the engine, but also when it is still cooling down after use, and must not be touched.
– Faulty wiring or incorrect operation of electrical equipment may lead to sparks forming, and must
be avoided as a potential fire hazard.
– Rotating parts must be shielded against accidental contact when the engine is installed in other
equipment or machinery.
Guards are available from HATZ to protect belt drives, cooling fans and generators.
– Before attempting to start the engine it is essential to have studied the starting information in the
Instruction Book.
– Mechanical starting devices must not be used by children or persons of insufficient physical
strength.
– Before starting the engine, ensure that all the specified protective guards are in place.
– The engine must only be operated, serviced or repaired by persons who have received the appro-
priate training.
– Keep the starting key out of reach of unauthorized persons.
– Never run the engine in closed or badly ventilated rooms.
Do not breath in emissions - danger of poisoning!
– Also fuel and lubricants could contain poisonous components. Please follow the instructions of the
mineral oil producer (safety data sheets).

4
Important notes on safe operation of the engine
– Stop the engine before performing any maintenance, cleaning- and repair work.
– Stop the engine before refuelling.
Never add fuel near a naked flame or a source of sparks.
Don’t smoke. Don’t spill fuel.
– Keep explosive materials as well as flammable materials away from the engine because the exhaust
gets very hot during operation.
– Wear close-fitting clothing when working on a running engine.
Please don’t wear necklaces, bracelets or any other things which you could get caught with.
– Please pay attention to all advice- and warning stickers placed on the engine and keep them in legi-
ble condition. In case a label has come off or is no longer clearly legible, it must be replaced imme-
diately. To this effect, please contact the HATZ service station in your area.
– Note that any unauthorized modification to the engine absolves its manufacturer from liability for
the consequences.
Regular servicing in accordance with the details provided in this Instruction Book is essential to keep
the operating reliably and to ensure the exhaust quality of the engine.
In case of doubt, always consult your nearest HATZ service station before starting the engine.

5
2. Description of engine
1
1 Oil filler pipe
2 Dipstick
3 Type plate
4 Combustion air intake
5 Dry-type air cleaner
6 Tank drain plug
7 Cylinder head cover
8 Tank filler cap
9 Cooling air inlet
10 Air cleaner maintenance indicator
11 Speed control lever
12 Oil filter (optional extra)
13 Fuel filter
14 Cooling air outlet
15 Silencer (muffler)
16 Starter motor
17 Central plug for electical system
18 Oil drain plug

6
3. General information
3.1. Technical data
Type 1D90.
Engine models V / W
Mode of operation air-cooled four-stroke diesel engine
Combustion method Direct-fuel injection
Number of cylinders 1
Bore / stroke mm 104 / 85
Displacement cm³ 722
Engine oil content without filter approx. L 1.5 1)
with filter approx. L 1.6 1)
Volume of oil between
„max“ and „min“ marks approx. L 0.7 1)
Consumption of lubrication oil
after running-in period approx. 1 % of fuel consumption at full load
Engine oil pressure
Oil temperature 100 ± 20 °C min. 0.6 bar at 850 r.p.m.
Direction of rotation
looking at the flywheel counterclockwise
Valve clearances at 10 - 30 °C
Inlet mm 0.30
Exhaust mm 0.30
Max. angle from vertical in any
direction (continuous operation) max. 25° 2)
Weight (incl. fuel tank, air-cleaner,
exhaust silencer and electric starter)
Engine models V approx. kg 106
Engine models W approx. kg 108
Battery capacity min / max 12 V - 45 / 88 Ah •24 V - 36 / 55 Ah
Model V: normal system of balancing, counterclockwise rotation
W: add. system of balancing, counterclockwise rotation
1) These data are approx.-values. The max. mark on oil dipstick counts, fig. 6.
2) Exceeding these limits causes engine breakdown.

3.2. Transport
2
Location for suspension lugs „1“,
please see picture 2.
Suspension lugs serve for save engine trans-
port. They are not suitable and allowed for
lifting complete machines.
3.3. Instructions for installation
If you have an engine which is not yet installed
in a machine and still has to be installed, make
sure that the Assembly Instructions for HATZ
Diesel Engines are complied with prior to instal-
lation. These Assembly Instructions contain im-
portant information about safe assembly of the
engine and restricted engine use of EPA/CARB
certified engines.
These instructions are available from the HATZ
service center in your area.
Pending complete installation, the engine
must not be started !
Moreover, we would like to point out that in this
case, commissioning of the machine is also pro-
hibited until it has been verified that the machine
into which this engine is to be incorporated
complies with all the safety precautions and reg-
ulations provided by law.
Refer also to the Declaration for Incorporation
at the end of these Operating Instructions.
3
The permitted loads and elements on
the speed adjusting lever and the stop
lever should be observed as an exess can lead
to damage to the contacts and inner governor
parts.
3.4. Load on engine
See supplemental information for EPA certified
engines, Page 31.
7

3.5. EPA/CARB-type plate and
fuel label
The layout of the EPA /CARB - type plate depends
on the engine application and is placed on the
crankcase (chapt. 2).
It includes the following emission control infor-
mation (Figure 4a):
Type plate
4a
➀EPA / CARB - Engine Family Number
➁engine type / spec. (only for special
equipment) /Fuel Delivery Timing
➂engine number
➃max. engine rated speed
➄build date
➅displacement
➆rated power
➇emission control system information (see
page 34)
➈“variable speed” or “constant speed only”
(if requested)
The type plate also states the applicable emis-
sion-related power category of the engine.
The figure of the lable shows a EPA/CARB (50
states) label. The text referring to the emission
regulation gets printed depending on the engine
equipment (EPA or EPA and CARB).
Every engine is equipped with an additional
loose engine type plate. If the original type
plate on the engine is not readily visible after
the engine is installed in the equipment then
the second loose type plate must be attached
on the equipment in such a manner that it is
readily visible to an average person.
For any offer as well as spare parts orders it is
necessary to mention the following data (also
see spare parts list, page 1):
➁engine type / spec.
(only for special equipment)
➂engine number
➃max. engine rated speed
Always install the engine for its intended applica-
tion in order to comply with EPA and CARB
emission regulation requirements.
Fuel label
4c
The engine must be operated with “ULTRA LOW
SULFUR FUEL ONLY”.
The fuel label is placed nearby the fuel inlet.
If there was no fuel tank mounted to the engine,
the label has to be permanently attached to the
equipment near the fuel inlet.
3.6. EMISSION-RELATED
INSTALLATION INSTRUCTIONS
See supplemental information for EPA certified
engines, Page 31.
0000 053 657 02
VARIABLE SPEED. ULTRA LOW SULFUR FUEL ONLY.
Power Category:
EMISSION CONTROL SYSTEM INFORM.:
➀
➁
➂
➃➄
➅
➆
➈
➇
8

4. Operation
4.1. Before initial start-up
Engines are normally delivered without fuel and
oil.
4.1.1. Engine oil
Oil quality
Qualified are all trademark oils which fulfil at
least one of the following specifications:
ACEA – B2 / E2 or more significant
API – CD / CE / CF / CF-4 / CG-4 or more
significant.
If engine oil of a poorer quality is used, reduce
oil change intervals to 150 hours of operation.
Oil viscosity:
5
Please select the recommended viscosity de-
pending on the ambient temperature at which
the engine is operated.
Inappropriate engine oil may shorten the
engine’s service life significantly.
The engine must be in a horizontal position be-
fore adding oil or checking the oil level.
6
– Remove oil fill screw „1“ and dipstick „2“.
– Add engine oil up to the max. mark on the
dipstick.
Lubricating oil capacity: see Chapter 3.1.
– Tighten oil fill screw by hand.
Attention !
If the engine is operated while the oil level is
below the min. mark or above the max. mark,
it can cause damage to the engine.
-40
-30
-20
-10
0
10
20
30
40
50
10 4
86
68
50
32
14
-4
-22
-40
OIL: SAE...
°C°F
5W/30
5W/40
10W/40
10W/30
15W/40
30
40
122
10 W
9

4.1.2. Fuel
Only refuel when engine is stopped.
Never refuel close to open flames or
flammable sparks, don’t smoke. Use only pure
fuel and clean replenishing cups. Don’t spill
the fuel.
All diesel fuels sold as fuel and complying with
the following minimum specification can be
used:
EN 590 or
BS 2869 A1 / A2 or
ASTM D 975 - 1D / 2D
Important !
The use of fuels of different specifications
requires the prior written consent of the HATZ
headquarters.
7
– Add diesel fuel to the fuel tank until it is at
leasthalf full.
The fuel system is bled automatically if the fuel
tank is attached to the engine or located higher
than the injection pump.
8
– If the fuel tank is not mounted on top of the
engine, or is at a lower level, operate the lever
on the fuel feed pump until fuel is heard to
flow back to the tank through the return line.
At temperatures below 0 °C, winter-grade fuel
should be used or parafin added to the fuel well
in advance.
Lowest ambient
temperature when
starting, in °C
Paraffin content for:
Summer Winter
fuel fuel
0 up to –10 20 % –
–10 up to –15 30 % –
–15 up to –20 50 % 20 %
–20 up to –30 – 50 %
10

4.1.3. Mechanical oil pressure
monitor (optional extra)
The mechanical oil pressure monitor should be
activated:
• when first filling, or after running the fuel tank
dry.
• if engine shut down automatically because
lubricating oil supply was inadequate.
– Add fuel, chap. 4.1.2.
– Check engine oil level, chap. 5.2.1.
9
– To activate the monitor, press lever „1“ for
approx. 15 seconds.
– If the engine has a fuel feed pump, operate its
lever for several strokes at the same time
(Fig. 8).
10
Instructions to activate the mechanical oil pres-
sure control are mentioned on the sticker placed
on the engine.
IMPORTANT !
Even with mechanical oil pressure monitoring
the oil level must be checked every 8 – 15
operating hours.
0000 051 268 02
1 3 4
56
2
7
15s
11

4.2. Starting the engine
Do not run the engine in closed or
badly ventilated rooms – danger of
poisoning ! Before the engine is started, al-
ways make sure that nobody is in the danger
area (moving parts on engine or machinery)
and that all safety guards are in place.
11
Never use any spray starting aids.
4.2.1. Preparations for starting
– If possible, disengage the engine from any
driven equipment.
The auxiliary equipment should always be
placed in neutral.
12
– Set speed control lever „1“ to a position be-
tween 1/2 START and max. START, according
to requirements.
Selecting a lower engine speed will reduce
smoke when starting.
– Make sure that stop lever „2“ - if fitted - is in
the operating „START“ position.
4.2.2. Electric starter
For preparations to start, see Chapter 4.2.1.
Starting procedure
13
1
2
3
4
5
12

– Insert start key and turn to position I (Fig. 13)
– Battery charge telltale „2“ and oil pressure
warning „3“ must light up.
– Turn start key to position II (Fig. 13).
– As soon as the engine runs, release the start
key. It must return to position I by itself and
remain in this position during operation.
The battery charge telltale and oil pressure
warning must go out immediately after start-
ing. Indicator light „1“ is on when the engine
is in operation.
– If anything seems to be incorrect, stop the en-
gine immediately and trace and rectify the fault
(chapt. 6).
– The engine temperature display „4“ (additional
equipment) lights up if the temperature at the
cylinder head becomes too high.
Switch off the engine and trace and elimi-
nate the cause of the problem, chapter 6.
– Always turn the start key back to position 0
before re-starting the engine. The repeat lock
in the ignition lock prevents the starter motor
from engaging and possibly being damaged
while the engine is still running.
Note:
Start for max. 30 seconds. If the engine does
not run after this time, turn starter key back to
position 0 and eliminate the cause, Chapter 6.
Never operate the electric starter when
the engine is running or coasting to a
standstill. There is a risk of broken starter pin-
ion or ring gear teeth.
Important !
If a starter protection module is installed, the
start key has to be returned to position 0 for at
least 8 seconds after the engine has failed to
start or after switching it off before a further at-
tempt can be made to start the engine.
Preheating device with automatic heating
timer (additional equipment)
The preheating light „5“ lights up additionally at
temperatures below 0° Celsius (Fig. 13).
– After the light has gone out, start the engine
without delay.
Automatic shut-down function
(additional equipment)
This is characterized by a brief flashing of all
pilot lamps once the starter key has been turned
to position I (Fig. 13).
Important !
If the engine cuts out immediately after starting
or switches off by itself during operation, a mon-
itoring element in the automatic shutdown sys-
tem has tripped. The corresponding indicator
light (Fig. 13, positions 2 - 4) will come on. After
the engine has stopped, the display continues to
glow for about 2 minutes.
The electrical device then switches itself off au-
tomatically.
The display lights up again after the start key
has been turned back to position 0 and then to
position I again.
Trace and eliminate the cause of the
operating fault before trying to restart the
engine (see chapter 6).
The display light goes out when the engine is
next started.
Even with automatic shutdown monitoring the
oil level must be checked every 8 – 15 operat-
ing hours (chapter 5.2.1.).
4.3. Engine use
Engines certified for constant or variable speed
within a certain operating range, must be operat-
ed according to the operator’s manual of the ma-
chine. Any changes in the speed adjustment sys-
tem are forbidden by law.
13

4.4. Stopping the engine
During breaks in work or at the con-
clusion of the working period, keep
the starting key in a safe place, out of reach
of unauthorized persons.
14
– Move speed control lever „1“ back to the STOP
position.
– On engines with the lower engine speeds not
accessible, move speed control lever „1“ back,
then move stop lever „2“ (optional extra) in the
STOP direction. Hold it there until the engine
has stopped.
– Once the engine is not running any longer,
release the stop lever. The stop lever is re-
turned automatically to its operating position
START via a spring.
15
The charge „2“ and oil pressure telltales „3“
come on.
– Turn the key to the 0 position and pull it out.
The telltale lights must then go out.
Note:
Engines with an automatic shut-down function
(chapter 4.2.2.), can also be switched off by
turning the start key back to position 0.
1
2
3
4
5
14

15
5. Maintenance
The engine must be stopped before any maintenance work is attempted.
Comply with legal requirements when handling and disposing of old oil, filters and
cleaning materials.
Keep the engine’s starting key out of reach of unauthorized persons.
Disconnect the negative battery terminal.
At the end of the maintenance work, check that all tools have been removed from the engine and
all safety guards, covers etc. replaced in their correct positions.
Before starting the engine, make sure that nobody is in the danger area (engine or driven
machinery).
5.1. Maintenance summary
Maintenace intervals Maintenance work required Chap.
Every 8 – 15 operating
hours or before daily
starting.
Check oil level.
Check area round combustion air input.
Check the air cleaner maintenance indicator.
Check the cooling air zone.
Check the water trap.
5.2.1.
5.2.2.
5.2.3.
5.2.4.
5.2.5.
Every 250 operating
hours
Replace engine oil and oil filter.
Check and adjust tappet clearance.
Clean cooling air system.
Examine screw connections.
5.3.1.
5.3.2.
5.3.3.
5.3.4.
Every 500 operating
hours
Replace fuel filter.
Maintenance of dry-air filter.
5.4.1.
5.4.2.
8- 15
500
250

16
The above maintenance chart is supplied with
every engine. This label should be affixed to the
engine or equipment in an easily visible position.
The maintenance chart governs the maintenance
intervals.
For new or reconditioned engines, the following
must always be carried out after first 25 operat-
ing hours:
– Replace engine oil and oil filter, chap. 5.3.1.
– Check tappet clearance, and adjust if neces-
sary, chap. 5.3.2.
– Examine screw connections, chap. 5.3.4.
Do not tighten the cylinder head fastening.
For short operating periods: replace engine oil
and oil filter after 12 months at the latest, re-
gardless of the number of operating hours.
16
IN EX
= 1h
1D41:
1D42:
1D50:
1D81:
1D90:
IN 0.1 mm
IN 0.1 mm
IN 0.1 mm
IN 0.1 mm
IN 0.3 mm
/
/
/
/
/
EX 0.2 mm
EX 0.2 mm
EX 0.2 mm
EX 0.2 mm
EX 0.3 mm
0000 040 483 05
1D..
500h
250h
max
OIL
max
DIESEL

5.2. Maintenance every 8 – 15
hours of operation
5.2.1. Check engine oil level
When checking the oil level, the engine should
be standing level, and must not be running.
– Remove any dirt in the dipstick area.
17
– For oil level inspection, remove the dipstick
and wipe it dry using a lint-free, clean piece of
cloth; then insert it to its stop and pull it out
again.
– Check oil level at the dipstick; top up if
necessary as far as the „max“ mark (see
Chapter 4.1.1.).
Attention !
If the engine is operated while the oil level is
below the min. mark or above the max. mark, it
can cause damage to the engine.
5.2.2. Check air intake point
Severe contamination is a sign that there are
large amounts of dust in the atmosphere and the
air cleaner maintenance intervals should be re-
duced.
– Depending on the air intake pattern, check
for severe blockage; clean if necessary
(see Chapter 2).
5.2.3. Air cleaner blockage indicator
(optional extra)
– Run the engine at full speed shortly.
18
If the rubber bellows is pulled in and obscures
the green zone „1“, maintenance work is due on
the air cleaner, Chapt. 5.4.2.
In dusty operating conditions, check the rubber
bellows several times a day.
max.
min.
17

5.2.4. Checking cooling air zone
Severe contamination is a sign that there are
large amounts of dust in the atmosphere and
that maintenance intervals should be reduced.
– Check the air inlet and outlet zones for block-
age by coarse material such as leaves, large
amounts of dust etc., and clean if necessary
(see chapters 2 and 5.3.3.).
If a temperature warning light „4“ is provided,
it will come on if the engine overheats
(Fig. 15).
In this case, stop the engine immediately
(Chapters 4.3. and 5.3.3.).
5.2.5. Checking the water trap
The intervals at which you should check the
water trap depend entirely on the amount of
water in the fuel and the care taken when re-
fuelling. The normal interval is once a week.
19
– Loosen hexagon screw „1“ with approx.
2-3 rotations.
– Trap the drops which emerge in a transparent
vessel. Since water has a greater specific grav-
ity than diesel fuel, the water emerges before
the diesel fuel. The two substances separate at
a clearly visible line.
– As soon as diesel only emerges at screw „1“,
this can be tightened again.
If an external water trap is attached, check its
water content every day, when the engine oil
level is checked.
The water which has collected is separated at a
clearly visible line from the diesel fuel above it.
20
– Open drain plug „1“ and drain the water out
into a suitable vessel.
If the drain plug is difficult to reach, an exten-
sion hose can be attached to it.
18

5.3. Maintenance every 250
hours of operation
5.3.1. Changing engine oil,
renewing oil filter
The engine must be stopped, and should stand
on a flat, level surface.
Drain the engine oil only when it is warm.
Danger of scalding from hot oil.
Trap the old oil and dispose of it in
accordance with local legislation.
21
– Unscrew the oil drain plug „1“ and allow all the
oil to drain out.
– Clean the oil drain plug and attach a new
seal „2“. Insert and tighten the plug.
22
– Renew the replaceable lubricating oil filter-
element (optional extra). Catch leaking oil !
Important !
Note the „TOP“ mark on the oil filter.
23
– Clean sieve bottom carefully in order not to
bend the netting. Wipe out cap screw or blow
it out with compressed air.
Persons handling compressed air must
wear protective goggles. Never direct
the jet to animals, persons or yourself !
– Check condition of O-ring „1“ and renew it if
necessary (Fig. 22).
19